Low profile pass-through electrical connector

ABSTRACT

A low profile pass-through electrical connector is designed for aerospace applications. The connector allows voltage and current to pass-thru a conductive wing surface, while maintaining a low profile height for aerodynamic performance considerations. Examples of applications of the electrical connector include power for thin film heaters and communication antennae applications.

RELATED APPLICATION

This application claims is a continuation of U.S. patent application Ser. No. 13/909,061, now U.S. Pat. No. 9,623,975 which was filed Jun. 3, 2013 and claims priority to U.S. provisional patent application ser. No. 61/654,787, filed 1 Jun. 2012.

SUMMARY OF THE INVENTION

The present invention is directed toward a low profile pass-thru connector for passing electrical voltage and current through a conductive wing surface, which are typically made of carbon fiber or aluminum. Preferably, the connector maintains a low profile height with respect to the wing surface, to maintain the wing's aerodynamic performance. The pass-thru connector may provide power to thin film heaters used for anti-icing/de-icing purposes, and can alternatively (or in combination) be utilized for other purposes such as communication antennas. Thin film heaters may require high electrical currents, so the pass-thru connector must have sufficient cross-sectional area where it travels through the wing to prevent overheating. It also should make a transition to a thin conductive (preferably copper) strip conductor to interface with the thin film heaters. This thin copper strip does not overheat with high current use because the airflow during flight keeps it cool due to forced convection. In one variant, the total thickness of the thin film heater cannot be more than 0.020 inches (0.51 mm), and to this end, the thin copper leads for this application are preferably 0.005 inches (0.013 mm) thick or less.

The invention includes any of the designs described herein including generalizations of these designs, portions of each design, as well as combinations of the designs. The invention also includes methods of making conductive assemblies and/or flying vehicles comprising the conductive assemblies. The invention also includes methods of using a heating element or antenna comprising using any of the conductive assemblies and/or flying vehicles described herein; for example, a method of deicing or heating an aerodynamic surface, or powering an antenna on an aerodynamic surface, comprising passing an electric current through any of the pass-through conductors described herein. Any of the inventive aspects can be described as forming a finished conductive assembly without solder. A nonlimiting list of the inventive concepts includes any of the following aspects.

In one aspect, the invention provides a conductive assembly, comprising: a heating element or antenna; an electrically conductive pin that is electrically connected to the heating element or antenna; a mating socket that is adapted to mate with the conductive pin; and an electrically insulating sleeve disposed around the circumference of the pin and/or mating socket.

In another aspect, the invention provides a flying vehicle (that is, a missile or manned or unmanned aircraft) comprising the conductive assembly disposed on an aerodynamic surface (preferably a wing) wherein the heating element or antenna is disposed on the exterior surface of the flying vehicle and the electrically conducting pin and mating socket form an electrical pathway from the exterior of the flying vehicle to the interior (for example, from the surface of a wing to the interior of the wing). In some preferred embodiments, there is no solder on the conductive pin. In some preferred embodiments, the electrically insulating sleeve comprises a threaded polymer and the pin is a screw-type pin that is adapted to screw through the threaded polymer.

The invention also includes a method of making a conductive assembly or flying vehicle comprising any of the assembly steps described herein. In some embodiments, a conductive assembly comprising a heating element (in some embodiments, a plurality of heating elements) or an antenna and having one or (usually) more conductive pins is pressed through aperture(s) formed by an electrically insulating sleeve(s) that is (are) disposed in and pass through the surface of an airfoil. The electrically conductive pin(s) mate with a socket(s) to form an electrical pathway through the airfoil surface. In some preferred embodiments, no solder is required to install the conductive assembly on the airfoil surface.

In another aspect, the invention provides a method of conducting electricity from the inside to the outside of an airfoil (or vice versa), that comprises passing electricity through the electrically conductive pin. In a preferred embodiment, this method is conducted while a fluid passes over the surface of the airfoil at a velocity of at least 200 mph (320 km). This condition would typically be encountered during flight but would not be experienced by a structure on the ground.

In a further aspect, the invention provides a flying vehicle comprising an airfoil (such as a wing) comprising a conductive wire passing from the inside of the airfoil to the outside of the airfoil and an insulating sleeve disposed around the conductive wire. Preferably, the insulating sleeve is fit by compression into the airfoil. In some embodiments, the conductive wire is a screw that has a flat head that conforms to the surface of the airfoil.

In yet another aspect, the invention provides a conductive assembly, comprising: a heating element or antenna; an aerodynamic surface; a connector base forming a pathway through the aerodynamic surface; a floating center disposed inside the connector base; and an electrical conductor disposed within the floating center. The invention also includes a flying vehicle comprising this conductive assembly, the corresponding methods of making these assemblies, and the corresponding methods of using the heating elements or antennas. The floating element can be loose and able to move in the x and y directions while remaining immobile in the z-direction; in this case, the assembly is typically an intermediate structure. The intermediate structure can be treated with an adhesive that secures the copper conductor (or other strip conductor) and/or the heating element and/or the antenna; the adhesive also secures the floating center so that is no longer floating. The connector base is typically cylindrical. The connector base and floating center preferably have the same length. The connector base may have a rim that retains a cylindrical floating center or an eyelet in the airfoil surface can retain the floating center. In preferred embodiments, a snap ring (also called a retainer ring) prevents the floating center from moving up through the airfoil surface and preferably immobilizes the floating center in the z direction (that is, the direction normal to the airfoil surface). Preferably, a retaining ring is disposed around and at the top part (that is, the part nearest the airfoil surface) of the floating center. In one embodiment, the retainer ring is a cut circle that snaps into place; this ring may have a c-shape that acts as a spring by pressing against the rim of the connector base. Typically, the floating center contains a socket. The socket can complete the electrical connection from the interior of an airfoil to a heater element or antenna on the surface of the airfoil. As with other aspects of the invention, the heater element or antenna can be plugged into (or removed from) the socket in the floating center. In some embodiments, the top portion of the connector base and the floating center form a groove that can be filled by an adhesive that anchors the floating center and may also secure the heating element or antenna to the airfoil surface. Desirably, the connector base and floating center are electrically insulating.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-3 illustrate a low profile pass-through electrical connector comprising an electrically conductive pin passing through a non-conductive sheath.

FIGS. 4-6 illustrate a low profile pass-through electrical connector in which a copper lead is sandwiched between a steel screw and an insulating sleeve.

FIGS. 7-9 illustrate a low profile pass-through electrical connector in which the use of a conductive screw avoids the use of solder to fasten the conductive lead.

FIGS. 10-13 illustrate a low profile pass-through electrical connector comprising a pin and socket.

FIG. 14 illustrates an assembly comprising multiple thin film heaters stacked in close proximity.

FIGS. 15-18 show photographs of low profile pass-through electrical connectors.

FIG. 19 illustrates a floating pass through connecter (far right), connector base (far left), and floating center (center).

DETAILED DESCRIPTION OF THE INVENTION

While various embodiments of the present invention are described herein, it should be understood that they have been presented by way of example only, and are not intended to limit the invention.

In one embodiment, the invention provides a low profile pass-through electrical connector that connects or is adapted for connecting an electrical conductor on a outer surface of a plane wing to conductors in the interior of the plane wing, comprising: a conductive pin (e.g., a brass pin of 12-14 gauge); a non-conducting vented fastener for receiving the pin; a captive nut configured to thread around the fastener in the interior of the wing; a non-conductive sheath; a micro jack connector press fit into the non-conductive sheath; and a wire.

Referring to FIGS. 1-3, a low profile pass-through electrical connector 10 comprises: a conductive brass pin 15 of 12-14 gauge; a ¼-20 size ( 1/4 inch diameter, 20 threads per inch; 0.64 cm diameter, 8 threads per cm) non-conducting vented fastener 20 that has been modified for fitment of a brass conductor; a captive nut 25; a micro jack connector 30, press fit into the non-conductive sheath; a non-conductive sheath 35; and a wire 40. FIG. 2 illustrates a cutaway view of the assembled pass through connector, with a solder joint 23 where the thin copper lead 24 connects to the head of the 12-gauge pin. FIG. 3 is a bottom view of the pass through connector assembly.

In another embodiment, referring to FIGS. 4-6, a low profile pass through electrical connector 45 comprises: a number 10, 100-degree ( 25/64 inch, 0.99 cm nominal diameter, 100 degree is the angle formed by the tapered screw head) flat-head stainless steel screw 50; a wide flange nylon insulating sleeve 55; a wide nylon insulating washer 60; a copper ring terminal with solder flange 65; and a captive nut 70. FIG. 4 is an exploded view and FIG. 5 is a cutaway view of an assembled connector. The thin copper lead 52 is sandwiched between the head of the screw and the nylon sleeve in this concept to complete the electrical connection. This obviates the need for a solder joint.

In a further variant, referring to FIGS. 7-9, a low profile pass through electrical connector 100 comprises a copper lead 105 that has been cut with an eyelet shaped feature 110 on one end. This eyelet shape is then swaged into a countersink shape. The countersunk eyelet provides for a large contact area for the thin copper lead.

FIGS. 7-9 illustrate a compression connection without the need for any solder connections. This design uses a polymer insulating insert 114, made from a material such as Noryl™, that is fastened to the wing surface by means of a threaded nut 11. The head of the insert has a countersink shape, which allows it to mount flush to the wing surface with a countersunk hole in the wing. The inside of the insert 114 is also threaded, and a conductive screw 88 (such as aluminum) is threaded into it as the pass-thru conductor. The screw also has a countersunk head, which sandwiches the countersink shape of the swaged copper lead 92 into the head of the insulating insert. FIG. 7 is a top view, FIG. 8 is a cutaway view and FIG. 9 is a close-up cutaway showing the compression fit.

In another example, referring to FIGS. 10-13, the low profile pass-through electrical connection comprises:

-   155—a flattened conductive lead (preferably copper). -   160—conductive pin. -   165—electrically insulating sleeve. -   170—conductive socket for mating with the conductive pin. -   175—electrical power wire.

FIGS. 10-13 illustrate a mated pin and socket connection. MIL-SPEC (United States military specifications) pins and sockets improve the shock—and vibration—resistance of the connection. The mated pin 160 and socket 170 connection uses a comparatively smaller area, allowing a greater density of connections to be made. This can improve the performance of the thin film heater by allowing a higher resolution of individual heater control. A conductive wire (such as wire 40) can be connected to socket 170 by crimping or soldering. Typically, the socket 170 is potted in place. A preferred potting compound is an epoxy that produces a seal that is air and water tight. As can be seen in the drawings, on the airfoil-surface-facing side of socket 170 there is a hollow receptacle for receving the conductive pin 160. Preferably, surfaces for electrical connections are gold plated. The thin film heater 195 can be removed and replaced without having to undo any internal wiring connections since the socket is fastened to the insert.

FIG. 10 illustrates a mating receptacle in an exploded view. FIG. 11 is an exploded cutaway view, and FIG. 12 is an illustration of a mated pin and socket cutaway. FIG. 13 shows a cutaway of the complete thin film heater assembly, including the wing section.

FIG. 14 illustrates a heater and pass-thru assembly 196 illustrating multiple thin film heaters 198 can be stacked in close proximity using a tiled approach with a pass-thru connector design.

FIGS. 15-18 illustrate example embodiments of the low profile pass through electrical connection comprising a mated pin and socket connection.

FIG. 15 is a photograph of insert receptacle assemblies installed in a wing surface. FIG. 16 is a photograph of thin film heaters with a pin mating interface. FIG. 17 is a photograph illustrating a mating of pin with insert receptacle. FIG. 18 is a photograph of an inside of a wing showing pass-thru receptacle wiring.

The floating pass through connector is illustrated in FIG. 19. The illustrated floating pass through connector 102 is comprised of 4 main parts: the connector base 104, the floating center 106, the socket (not visible in FIG. 19), and the snap ring 108. The interior of floating center 106 can be identical to the interior of electrically insulating sleeve 165. Similarly, the socket is inserted into the floating center and potted in-place with an electrical wire. The connector base 104 is epoxied in-place into the wing surface. The floating center 106 is then installed into the connector base, and is held in place by the snap ring (also called a retainer ring). The floating center can move laterally in the X and Y-plane, but the snap ring prevents it from moving axially. Once a thin-film heater is applied onto the wing surface, the epoxy used to apply the heater fills the groove 110 where the snap ring resides. This solidifies the connector, adds structural strength, and prevents movement in the future. The floating aspect only needs to be utilized during the assembly phase; however, the part may still be termed as a floating center after fixing in place by an adhesive.

This floating design allows for the connector to tolerate an additional .020″ inch (0.5 mm) of tolerance from the pin connection without causing the thin film plastic heater to stretch or wrinkle. This is especially important when installing several connector into a wing surface as maintaining the hole position tolerance is very challenging. The connector design maintains its flush surface mount properties to ensure aerodynamic performance. A vibration test has been performed on this connector design without any failures. 

1-13. (canceled)
 14. A method of removing and replacing a thin film heater from a wing, comprising: providing a wing comprising a first thin film heater disposed on the surface of the wing, one or more electrically conductive pins that are electrically connected to the first thin film heater, and one or more mating sockets under the surface of the wing that are mated with the conductive pin; lifting the thin film heater away from the surface of the wing without accessing the inside of the wing and without undoing any wiring connections inside the wing; and pressing a conductive assembly comprising a second thin film heater having one or more conductive pins through one or more apertures formed by one or more electrically insulating sleeves that are disposed in and pass through the surface of the wing, wherein the electrically conductive pins mate with the one or more sockets to form an electrical pathway through the airfoil surface without accessing the inside of the wing and without undoing any wiring connections inside the wing.
 15. The method of claim 14 wherein the first and second thin film heaters comprise plural conductive pins.
 16. The method of claim 15 wherein the plural conductive pins have smooth surfaces.
 17. The method of claim 14 wherein the one or more mating sockets comprise: a non-conductive sheath and a micro-jack connector that is press-fit into the non-conductive sheath.
 18. The method of claim 14 wherein the one or more electrically conductive pins on the first and second thin film heaters comprise a countersunk head that is disposed in a countersunk orifice in the surface of the wing.
 19. The method of claim 18 wherein the one or more mating sockets comprise: a non-conductive sheath disposed in the orifice.
 20. The method of claim 19 wherein the one or more electrically conductive pins on the first and second thin film heaters comprise screws and wherein the non-conductive sheath is threaded.
 21. The method of claim 16 wherein surfaces on the one or more electrically conductive pins and on the one or more sockets are gold-plated.
 22. The method of claim 16 wherein the one or more sockets are potted in place by an epoxy.
 23. A conductive assembly, comprising: a heating element or antenna; an electrically conductive pin having a smooth surface that is electrically connected to the heating element or antenna; a mating socket that is adapted to mate with the conductive pin without a nut; and an electrically insulating sleeve disposed around the circumference of the pin or mating socket.
 24. The conductive assembly of claim 23 wherein the electrically conductive pin comprises a countersunk head that is disposed in a countersunk orifice in the electrically insulating sleeve.
 25. The conductive assembly of claim 23 wherein the socket is potted in place by an epoxy.
 26. A conductive assembly on an airfoil, comprising: multiple thin film heaters stacked in close proximity to each other; a plurality of electrically conductive pins that are electrically connected to each of the thin film heaters in the conductive assembly; a plurality of mating sockets that are adapted to mate with the conductive pins; and a plurality of electrically insulating sleeves disposed around the circumference of the pins or mating sockets.
 27. The conductive assembly of claim 26 wherein the multiple thin film heaters are disposed in a planar array.
 28. The conductive assembly of claim 26 wherein the plurality of conductive pins have smooth surfaces that are disposed in the plurality of electrically insulating sleeves and that form interfaces with the mating sockets.
 29. The conductive assembly of claim 26 wherein the multiple thin film heaters are disposed in a unitary array. 